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EDIT 02-27-2012 : I make a comparative of 3 pouches dimensions i found on the site (Batninja, TK409 and Rafal).The result show that i need to make some modifications to my template to be more accurate.EDIT 02-26-2012 : Second part achievedEDIT 02-25-2012 : Flap and sewing finished. Begin how-to attach flap on pouchEDIT 02/22/201 : Second part of the tutorial started (see below)EDIT 02/21/2012 :
The first part of the tutorial is now complete.
The second part will concern the flap around the pouches and using magnet to maintain pouch closed.
The third part will be about weathering and how to adjust color if you can't find the right one
The last part will be the making of the belt

i guys!
It's my first contribution to this site. I begin to make an ammo belt for my costume and i have the idea to make it functionnal. I'm not the first to think it but my approach is differents than the others.
First i want to thank tk409 for posting pattern of the pouches. I use his work to make mines.
The pictures below show the first try with the pattern i designed.
Give me your opinion.

EDIT : These files corresponds to an ancient version. Please use those in Post #1.First part of the tutorial :

EDIT 02/21/2012 : I add a zip file with the pattern in formats wmf an adobe illustrator (the adjustments will be easier).

This is the pattern in 3 PDF (A4 format). In this version there will be no gap in front as shown in the precedents pictures.(it's not a real problem because it will be invisible when the pouch will be finished).
After you print the pdf and reconstitute the pattern, i recommend you glue it on cardboard to increase the strength.
In the last pdf, you will find the pattern for the wood pieces i use for the structure.
I use plywood of 3 or 4 millimeters of thickness. You can use also medium (i don't know if the name is the same in your country, it's wood reconstituted with particles and it's cheaper than plywood).
In my next message, i will post a step by step tutorial with pictures.

The first step :
1 - Print the wood pattern
2 - Glue it on cardboard (i use an old playmobil box)
3 - Cut the differents shapes
4 - Draw the shapes on the plywood (see the second picture to optimize the material)
5 - Cut the shapes

Step 2 : Cutting leather shape and assembling
1 - Print the 3 files, assemble them and cut the shape in paper
2 - To increase strenght, glue it on cardboard.
3 - This is th material i will use :
I think the color is a little too dark but i will try to correct this later.
4 - I use tape to maintain the pattern and i cut the shape using a cutter with a new blade.
5 - I use double side tape to stick the wood pieces
beware of the sides pieces, i make a mistake on mines because i stick tape on the same side.
I use a white pen to make marks on the backside of the leather shape. It's more easy to put correctly the wood pieces after.
6 - Stick the differents wood shapes using the second side of the tape.
I use matches to keep a space between the front, bottom and back pieces.

7 - glue the font and back parts
8 - glue the rectangular parts of the sides
9 - glue the last part of the sides
I use a battery to press the joint between the 2 parts.
10 - A this step, some adjustments will be necessary. Because tickness of the materials you use may be different than me, you will need to adjust some dimensions of the pattern.
11 - after the adjustments

1 - This is all the parts :
the leather part (cut with the template i will ppost tomorrow)
a cardboard rectangle : it adds more rigidity to the flap (i use thin cardboard so you can make the sewings with sewing machine)
a metal plate( cut in an old pc power supply case)
a neodymium magnet (you can find them on ebay for 3 or 4$ for 20 pcs)
2 - Use double side adhesive tape to stick the metal part on the cardboard
3 - Use double side tape to stick the cardboard with the metal plate on the leather (you can make marks to help you center the cardboard)
4 - Glue the magnet (caution : you must stick it on the other extremity)
5 - Use glue to stick each half of the leather part
6 - I stick the end of the flap apart because of the magnet

7 - Cut the angles
The result ( the sewing are missing, color is needed at some points but you can see that the mechanism is invisible)

Thank you very much clonecollector!
Here is a second version (make with the advice of RafalFett, thanks again to him). I made it quickly so the quality of work isn't very good.
I think the shape is good.The only thing i will change perhaps is the cormers of the flap ( i think that i cut a too big part)
If you agree with it RafalFett, i will produce the new template.

note : i find on tk409 site a very useful link talking about differents Boba belts
I see for example than the ESB belt has only 2 grommets while ROTJ belt has 6 grommets
Here is the link : Fett Ammo Belt

I'm sorry, my comment wasn't very clear.
I'm the author of the templates. I used tk409 one only to have the dimensions of the pouches.
In my last post, my question was only if you think that the shape is correct with the modifications before i post a new template.
Thank you again for your very quick response. I have finished the new template with a lot of improvments.
I will make a last try before posting it.
I make modification on flap template too.

I'm sorry, my comment wasn't very clear.
I'm the author of the templates. I used tk409 one only to have the dimensions of the pouches.
In my last post, my question was only if you think that the shape is correct with the modifications before i post a new template.
Thank you again for your very quick response. I have finished the new template with a lot of improvments.
I will make a last try before posting it.
I make modification on flap template too.

My mistake! I don't see any measurement on your files, but my calculations says that the ammo pouch should have this hight:

8 - Sewing :
Due to the fact that i haven't a sewing machine and no money to buy it i decide to make sewing by hand :
I make a template and stick it on heavy cardboard.
I use a dremel with an 1 mm metal drill
I use a leather needle and make the sewing (it takes 30 min to make holes and half sewing)

For this flap, i used sevaral parts of cardboard (one for each side of the pouch) with an interval of 3mm. The result is that the flap takes shape more easily.

When i will finished this one, i will post all the templates corrected.

For the dimensions, i use tk409's template
Some dimensions are differents (for example height of the pouch is 8,5 cm). What is the better between batninja template and tk 409 's one ?

And the last part of assembly :
I glue the front, bottom parts of the flap. For the back, i use a cardboard template to make holes in the flap and the pouch.
I sewed the flap on to the pouch at the top and bottom
And here's the result

I agree with RafalFett to keep the "rounded" flaps. It was just a test but result is less accurate.